High efficiency electric motor and power cogeneration unit

Abstract

A method and apparatus for reducing drag in an electric motor-power cogenerator is provided. Wound pole irons are formed around a stator having slots containing induction windings. Ends of the pole irons extend into or near the slots and are supported by a support structure that forms an opening. Other ends extend towards the opening. Stator inserts containing free-wheeling permanent magnet inserts are distributed around a rotor inserted into the support structure opening. The permanent magnet inserts are inserted into cavities along the periphery of the rotor and include a pair of pole sections with a first magnetic polarity and a second magnetic polarity. The windings of the pole irons are sequentially energized to provide a moving field and a torque to rotate the rotor. The permanent magnet inserts freely rotate into alignment with ends of the pole irons to increase a flux density and reduce drag.

1 . A method for reducing drag in an electric motor-power co-generator comprising:
 forming a series of wound lateral pole irons around the inner periphery of a stator, the stator having slots disposed around the inner periphery, the slots containing induction windings, first ends of the lateral pole irons extending into the slots, the lateral pole irons supported by a lateral pole iron support structure forming a circular opening concentric with the inner periphery of the stator, second ends of the lateral pole irons extending towards the circular opening;   distributing stator inserts containing free-wheeling permanent magnet inserts along an outer periphery of a rotor inserted into the circular opening of the lateral pole iron support structure, the free-wheeling permanent magnet inserts inserted into cavities along the outer periphery of the rotor, the permanent magnet inserts each having a pair of pole sections with a first magnetic polarity and a second magnetic polarity; and   sequentially energizing the windings of the lateral pole irons so as to provide a moving field to generate a torque applied to rotate the rotor, and pole sections of the free-wheeling permanent magnet inserts being free to rotate into alignment with ones of the second ends of the lateral pole irons to increase a flux density in the lateral pole irons, the first ends of the lateral pole irons inducing a current flow into the induction windings.   
     
     
         2 . The method of  claim 1 , further comprising:
 dividing the stator, the support structure, and the rotor into N equally spaced sectors by radii emanating from a common center point on a common central longitudinal axis and inserting the free-wheeling permanent magnet inserts into positions along the outer periphery of the rotor;   forming N/2 groups of two of the N equally spaced sectors; and   winding first ones of the lateral pole iron windings in first ones of the sectors in the N/2 groups such that the first lateral pole irons have a first magnetic polarity and winding second ones of the lateral pole iron windings in second ones of the sectors in the N/2 groups such that the second lateral pole irons have a second magnetic polarity.   
     
     
         3 . The method of  claim 1 , wherein the slots, the lateral pole irons and the free-wheeling permanent magnet inserts are axially aligned along a respective lengthwise axis thereof such that a lengthwise axis of the free-wheeling permanent magnet inserts is in normal alignment with a depthwise axis of the slots and lateral pole irons. 
     
     
         4 . The method of  claim 1 , further comprising magnetically shielding the free-wheeling permanent magnet inserts within the rotor such that flux generated thereby is coupled directly into the second ends of the lateral pole irons so as to minimize flux leakage and magnetic drag. 
     
     
         5 . The method of  claim 1 , wherein the distributing the free-wheeling permanent magnet inserts further includes inserting the free-wheeling permanent magnet inserts into respective openings provided in the rotor, the respective openings arranged in lengthwise alignment with the slots and the lateral pole irons, the openings corresponding to a longitudinal opening of the slots, to provide magnetic communication with the corresponding second ends of the lateral pole irons. 
     
     
         6 . The method of  claim 1 , wherein the sequentially energizing the windings of the lateral pole irons so as to provide a moving field includes bringing first ones of the free-wheeling permanent magnet inserts into alignment with first ones of the second ends of the lateral pole irons such that, as the torque is provided to rotate the rotor, the first ones of the free-wheeling permanent magnet inserts maintain the alignment with the first ones of the second ends of the lateral pole irons such that, as the rotor rotates past the second ends of the lateral pole irons, a maximum flux density associated with the moving field is maintained so as to induce a maximum current flow in the induction windings and reduce a magnetic drag associated with the rotation. 
     
     
         7 . The method of  claim 1 , wherein N is equal to 12. 
     
     
         8 . The method of  claim 1 , further comprising forming the pole sections from neodymium. 
     
     
         9 . The method of  claim 1 , further comprising forming the pole sections from samarium-cobalt. 
     
     
         10 . An electromagnetic assembly for an electric motor and power co-generation comprising:
 a stator having a plurality of slots arranged on a stator periphery of an inner stator opening thereof;   a plurality of lateral pole irons coupled to the stator such that first ends of each of the plurality of lateral pole irons are coupled to respective ones of the plurality of slots, the slots and the lateral pole irons aligned along a lengthwise and depthwise axis, the plurality of lateral pole irons supported by a support structure that is positioned within the inner stator opening on a common central axis, the support structure having a support structure opening in the center thereof, the lateral pole irons having windings and second ends directed toward the support structure opening; and   a rotor positioned within the support structure opening, the rotor having a plurality of cavities on a rotor outer periphery, the rotor coupled to a central shaft; and   a plurality of free-wheeling permanent magnet inserts inserted into the cavities, each of the plurality of free-wheeling permanent magnet inserts has a pair of magnetic pole sections having a first magnetic polarity and a second magnetic polarity, each of the free-wheeling permanent magnet inserts being capable of rotating about a longitudinal axis,   wherein the windings of the plurality of lateral pole irons are sequentially energized to create a moving field and a torque on the rotor causing a rotation of the shaft, the free-wheeling permanent magnet inserts rotating into alignment with the second ends of energized ones of the lateral pole irons and free-wheeling to maintain alignment as the rotor and the field rotates so as to provide maximum flux density in the lateral pole iron and the induction windings in a corresponding one of the plurality of slots to induce a current flow therein.   
     
     
         11 . The electromagnetic assembly of  claim 10 , wherein the stator, the support structure and the rotor are divided into N equally spaced sectors by radii emanating from a common center point on a common central longitudinal axis. 
     
     
         12 . The electromagnetic assembly of  claim 10 , further comprising an activation circuit coupled to the windings of the lateral pole irons, activation circuit applying three phases of alternating current power to sequentially energize ones of the windings of the lateral pole irons. 
     
     
         13 . The electromagnetic assembly of  claim 10 , further comprising an activation circuit coupled to the windings of the lateral pole irons, activation circuit including a rectifier circuit for applying rectified versions of three phases of alternating current power to sequentially energize ones of the windings of the lateral pole irons. 
     
     
         14 . The electromagnetic assembly of  claim 10 , wherein each of the plurality of the lateral pole irons are disposed respectively above each of the plurality of the slots such that the induction coil windings disposed in the plurality of slots are exposed to a concentrated amount of magnetic flux generated when the windings of the lateral pole irons are energized and a magnetic circuit is completed by the free-wheeling permanent magnet inserts. 
     
     
         15 . The electromagnetic assembly of  claim 10 , wherein the plurality of free-wheeling permanent magnet inserts are further capable of rotating in synchronized relation with the magnetic field such that when the windings of the lateral pole irons are sequentially energized, the free-wheeling permanent magnet inserts are rotated into alignment with the second ends of the lateral pole irons so as to provide maximum flux density in the induction windings to induce a current flow therein and to reduced magnetic drag on the rotor. 
     
     
         16 . The electromagnetic assembly of  claim 10 , wherein each of the cavities has an opening capable of being positioned adjacent to the second ends of the lateral pole irons. 
     
     
         17 . The electromagnetic assembly of  claim 10 , wherein each of the plurality of free-wheeling permanent magnet inserts is contained within a containment sleeve that shields the rotor from magnetic fields produced by each of the free-wheeling permanent magnet inserts. 
     
     
         18 . The electromagnetic assembly of  claims 17 , wherein the containment sleeve is made from alternating layers of mu metal and austenitic steel. 
     
     
         19 . The electromagnetic assembly of any of the preceding claims, wherein each of the stator and the support structure has a substantially circular shape. 
     
     
         20 . The electromagnetic assembly of  claim 10 , wherein each of the plurality of free-wheeling permanent magnet inserts is contained within a containment sleeve having one or more bearings to support rotation of the containment sleeve and the contained free-wheeling permanent magnet insert member. 
     
     
         21 . The electromagnetic assembly of any of the preceding claims, wherein the pole sections are formed from neodymium. 
     
     
         22 . The electromagnetic assembly of any of the preceding claims, wherein the pole sections are formed from samarium-cobalt. 
     
     
         23 . The electromagnetic assembly of  claim 10 , further comprising a rectifier circuit.